Metallic structure and method of making the same



May 28, 1935. w. DE FRIES METALLIC STRUCTURE AND METHOD OF MAKING THESAME Filed June 23, 1931- 4 Sheets-Sheet 1 INVENTOR 'W. DE FRIES May 28,1935.

I 2,603,138 METALLIC STRUCTURE AND METHOD OF-MAKING THE SAME 4 SheetS-Sheet 2 Filed June 23, 1931 May 28,1935. w. DE FRIES' 2,063,138

METALLIC STRUCTURE AND METHOD OF MAKING THE SAME File d June 23', 1931 4Sheets-Shee t s May 28, 1935. w. DE FRIES 2,003,133

' METALLIC STRUCTURE AND METHOD OF MAKING THE SAME Filed June 25, 1931 4Sheets-Sheet 4 meme Ma 28, 1935 2,003,133

UNITED STATES PATENTIOFFICE METAIQLIO STRUCTURE AND METHOD OF MAKING THESAME Walter de Fries, Youngstown, Ohio, assignor to The William B.Pollock company, Youngstown, Ohio, a corporation of Ohio ApplicationJune 23, 1931, Serial No. 546,271

' 21 Claims. (01. 29-1 4) -The present invention relates broadly to thetrating a difierent form of car body embodying building or fabricationof metallic structures, the present invention; v and more particularlyto structures adapted to Figure 9 is aside elevational view'of thestrucbe utilized as beams, girders, bodies and 'the ture illustrated inFigure 8;

s like, although the utility of the invention is Figure '10 is'a detailsectional view on the line. 5

not limited with respect to the particular use XX of Figure 9, lookingin the direction of the to which the structures are placed, .or'thepararrows;

ticular cross sectional characteristics" or desig- Figure 1 1'is adetailsectional view on the line nation thereof. XIXI of Figure 10,looking in the direction of 1 Ithas heretofore been customary in manythe arrows; and 10 cases to construct so-called box girders or beamsFigure 12 is a detail sectional view along the from a "series of rolledshapes suitably riveted line XlI-XII of Figure 10, looking in thedirecor welded one to the other. Box girders have tion of the arrows.

desirable structural characteristics which are With ordinary rolledshapes, the limitations of- ]5 well recognized. In many cases, however,it has the rolling operation require the shape to be 15 heretofore beennecessary to utilize I-beams or either of substantially constant crosssectional the like in place of the more desirable box girdareathroughout the entire length thereof, or ers for the reason that thecross sectional diof very gradually and uniformly changing crossmensionsof the girders have been such, that it sectionalcharacteristics. In many cases it is dehas not been possible for a manto work from sired to provide a girder, beam, body or the like 20 theinside thereof as required for the assembly having a cross sectionmodulus at one point operations and more especially the riveting whichis materially different from the cross which has been required. sectionmodulus at a point but slightly removed The present invention has forone of its obtherefrom. It will be readily apparent that jects theprovision of an improved structure rolled shapes-do not lend themselvesto such 25 adapted to serve in the capacity of a box girderrequirements, andit has accordingly been necfor :example, a beam, or asupporting body. essary, where rolled shapes have been utilized, Whilethe invention is useful generally in the to eiiect more or less of acompromise, providing building art, it is herein shown more particuanaverage cross section .which is heavier than larly as applied todifferent features of railway the minimum cross section required atcertain 30 car construction. It is to be understood, howp in s, in ordert insur the ssa y tr n ever, that the drawings in this respect areillus- This has resulted in structures having a materi-.

' trative only. In the drawings: ally greater weight tharimecessary. Inthe case Figure. 1 is a top plan view of a portion of a of buildings,cars and the like, this has meant an car body constructed in accordancewith the unnecessarily large ad o d w a eque t present invention; 4reduction in the permissiblelive load possi- Figure '2 is a sideelevational view of the bilities. structure illustrated in Figure 1;Wherever possible, fabricated girders, such Figure 3 is a transversesectional view on a as 110?! girders, ave been ut i ed. In a y 40 lineIII-III of Figure 1, the section, however, hOWeVeT, he dimensions of thedesired illustrating a complete car body; girders have not been 'such asto permit fabrica- Figure 4 is a side elevational view of a, portion inthis manner. The present invention is tion of a girder constructed inaccordance with designed 0 P v de a buildingistructufe of the presentinvention and more particularly eral utility capable of beingeffectively fabricated adapted to be utilized as a side sill forladlecars r rdless of he cross ec ion l iz and lending and the like; a itselfto a change in the section modulus as re- Figure 5 is a longitudinalsectional view, on an q from Point to Point in Order 150 the enlargedscale, through a portion of the girder necessary strengthof Figured;Referring more particularly to Figures 1 to 3 Figure 6 is a transversesectional view, on an of the drawings, there is illustrated a car body50 enlarged scale, on a line VI -VI of Figure 4; w ch 'in y p t is ot ba nd Figure 7 is a transverse sectional view on an fled girderconstruction. It comprises a top. enlarged scale along the line VII-VIIof Figplate or flange 2 and a bottom plate or flange 3 ure 4, looking inthe direction of the arrows; spaced a distance determined by thedimensions Figure 8 is aview similar to Figure 1, illusdesired in thecompleted car. Extending lon- 55 gitudinally between the plates orflanges are webs l which are likewise disposed in spaced relationship.The webs are characterized by the provision at intervals therealong oflugs or projections '5 adapted to interfit with correspondingly shapedopenings in the flanges. By reason of this construction, the mere act ofassembly of the webs and flanges serves to afford a mechanical interlocktherebetween. Prior, however, to the complete assembly of the parts,diaphragm plates 6 are mechanically interlocked both with the webs andflanges. These diaphragm plates are illustrated as comprisingsubstantially rectangular plates having upper and lower projectionsl'and side projections 8. The side projections interlock with the webs4, while the upper and lower projections interlock with the flanges. I

The desired interlocked relationship having beenobtained during theassembly, the parts may be welded in position. This may be accomplishedin a variety of different ways. If desired, the diaphragm plates andwebs may be mechanically interlocked and welded as a unit adapted toreceive the upper and lower flanges 2 and 3, after which the projections5 and I from the webs and diaphragm plates respectively are welded inposition in the flanges.

In this manner there is provided a substantially unitary structurecomposed entirely of plate'or platelike' members which are bothmechanically interlocked and welded one to the other.

The spacing of the diaphragm plates may be varied in accordance with theload requirements,

this being governed by the permissible ratio be-.

their number and location enable the strengthrequirements at differentpoints to be satisfactorily met. This makes possible the use of standardplates for the production of fabricated structures in which the sectionmodulus or radius of gyration varies from point to point.

The provision of means for mechanically interlocking the parts isdesirable for the reason that the projections transmit by-mechanlcalmeans a certain portion of the load, thus re-' lieving stresses whichwould otherwise be imposed entirely on welded joints. This makespossible the use of lighter welds. and obviates the difliculties whichhave heretofore been experienced in the case of welds which were notproperly eflfected,

In the embodiment illustrated in the figures of the drawings justreferred, to, the top flange 2 is of materially greater width than thebottom flange, so as to overhang the edge portions thereof. Theoverhanging portion of the top flange may be reinforced by gussets 9having creasing the load carrying capacity of the car.

In Figures 4 to 7 of the drawings there is illustrated a slightlymodified embodiment of the invention. In these figures there is shownthe end portion of a car sill or girder comprising a top flange I2, abottom flange l4, and inner and outer webs I 5 and I 6 respectively. Inthis embodiment, the flanges and webs are shown as being of difierentthicknesses, the flanges being materially heavier than the webs.Extending between the flanges are diaphragm plates ll of such lengththat the end portions thereof will extend through suitably shapedopenings in the webs l5 and. I6 so as to be mechanically interlockedtherewith.

During the assembly of a structural member of the type illustrated inthese figures of the drawings, the diaphragm plates will be first weldedin position between the flanges as indicated by the reference characterl8. Thereafter, the webs will be applied so as to interlock with theprojecting ends of the diaphragm plates l1, and the webs and flangeswelded one to the other as indicated at I9. Thereafter the projectingends of the diaphragm plates may likewise be welded in position to thewebs. a construction provides a box girder or beam which may beeffectively utilized for any desired purpose. By providing the diaphragmplates with openings 20, provision is made for the running of conduits,cables, pipes or the like longitudinally of the beam structure. By

previously individually shaping the webs and,

flanges, the completed structure may have a contour such that it isadapted for use in the desired structural relationship to other parts.

In Figures 8 to 12 of the drawings there is shown a portion of a carframe in which all of the parts,a're composed either of structural orplatemembers and in which all of the parts are mechanically interlockedand welded, thus form-- ing what may be termed, for all practicalpurposes, a one-piece structure. From Figure 8 it will be apparent thatthe'car structure comprises side sills 22, which are of identicalconstruction, and which cooperate through the medium of welded andinterlocked joints, hereinafter described, with an end frame 23. InFigure 8 there is only shown one end of a car, it being apparent thatthe two ends are of similar construction. Each side sill comprises a topflange, 24 and a bottom flange 25 between which are welded webs 26.,These webs are formed with projections 21 which project through openingsin the flanges and are welded thereto.

Where it is desired to provide a greater section modulus, recourse maybe had to the provision of filler flanges 28 as shown inFigure 10, thesefiller flanges being' welded both to the main flanges and;to the webs..This provides in effect a laminated flange structure. In like mannerthe webs themselves may be reinforced throughout portions of theirlengths.r Where filler flanges are utilized, they are welded in positionbetween the webs before their main flanges are assembled thereon, theentire structure being subsequently welded at the desired points.

prising mechanically interlocked webs and flanges, as in the structuresalready described.

Where the beams or girders are utilized as sills and comprise differentportions angularly disposed, the projections 21 will conveniently beformed as indicated more particularly in Figure 9 with the end walls ofthe projections so in- Such ,There is thus formed a beam or girdercomclined that the flanges may be applied by a true lateral movement. Inother words, the ends offall of the projections will preferably be parael.

Extending transversely between the side sills 22 is a bar 29 whichpasses through'suitable slots both in the inner and outer webs, the endsofthe bar lying flush with the outer web of the sills. The outer web ispreferably formed from a plate of suitable dimensions to provideadjacent each end thereof a bracket 30 and a beam engaging portion "3|The inner web of each sill terminates short of the outer web and isadapted to abut at its end against the web of a beam 32. This beam is ofsuch length as to fit into a correspondingly shaped slot in the beamportion 3| so as to permit welding of the same therein. Projectingupwardly from the bar 29, as illustrated more particularly in Figure 11of the drawings, is a trunnion support ing plate 33 welded at its loweredge to the bar 29 as indicated at 34. Secured to its upper end is ahorizontally extending plate 35 welded 'at one edge to the plate 33and'at its opposite edge to the upstanding portion 36 of a deck plate31,

thus forming a girder with two flanges and a single web similar to arolled I or H beam shape. Extending between the trunnion supportingplate 33, the plate 35, the deck plate 31, the beam 32 and the bar 29,is a series of ribs 38. Each of these ribs is provided with a projection39 adapted to mechanically interlock with a correspondingly shaped slotin the trunnion supporting plate 33 and with a second projection 40adapted to mechanically interlock with the deck plate 31'. The trunnionsupporting plate is further braced by means of gussets 4| welded inposition between the same and the bar "29. By reference moreparticularly to Figure 9 of the drawings, it will be apparent that thetrunnion supporting plate 33 is likewise formed with end projections 42which extend through suitably shaped openings in the bracket portion 33of the outer web 26 so as to mechan 'ically interlock these parts.

Secured in position between the trunnion supporting plate 33 and theupstanding portion 36 of the .deck plate are bearing members 43,conveniently formed of cast iron. Thesebearings, as will be apparentmore particularly from Figure 12 of the drawings, are formedwithshoulders 44 adapted to overlie the upper edges of the respective platesso as to be held against. downward movement relatively thereto.Theplates and bearings arefurther held in position bythrough bolts orrivets 45. The bearings at their upper ends are shaped toprovidetrunnion supports .46 for cooperation with the end 13521111110118usually provided on ladles and the Intermediate the bearings 43 theupstanding portion 36 of the deck plate 31 is provided with an intumedflange 46 for stiffening purposes.

The ends of the flange 46 bear against the ad-. jacent ends of thebearings 43, and the inwardconveniently also formed of plate members, asillustrated. The end frame is' completed by side plates 50 whicharesuita'bly welded in position to the deck plate at the upper edge, andto the beam portions 3| of the'webs 26 at their ends 1 as indicated at5|.

they may likewisebe welded to the beam.

With the exception of the bearings 43 which are conveniently of castiron by reason of the strength and inexpensiveness of such material,

. the entire end frame is composed of plate members and structuralmembers, all of which members are mechanically interlocked and welded.This provides a one-piece frame, for all practical purposes, and oneiving a maximum of strength with a minimum weight: Any portion of theentire frame may. be reinforced or strengthened by the provision ofsuitable ribs,

or by the provision of stiffening laminations' welded thereto over anyportion thereof. The beam 32 is illustrative 'pf one type ofreinforcing, such reinforcing comprising ribs 53 welded in positionbetween the flanges and web of the beam. i

As before stated, ;the drawings selected for purposes of illustratingthe present invention are particularly directed to structures adaptedfor use in the construction of cars or car bodies. They arerepresentative, however, of built up structures which may-be utilizedfor any desired building purposes wherein strength combined withlightness is a desirable factor.

Attention has already been called to the fact that in accordance withthe present'invention, it is possible to pre-shape the individual partsutilized for the construction of a finished article. This constitutes animportant advantage, in, that it eliminates the difliculties attendant'upon the proper shaping of previously formed articles or bodies. lfhus,for example,

in the case of rolled beams, any after shaping operation tends, byreason of elongation, to thin down certain of the parts, andby'compression, to thicken other of the parts. By preshaping thecomponent parts, and afterwards assembling the same, the desired crosssectional characteristics may be maintained throughout the entire lengthof the article.

In the illustrated embodiments of the invention, I have shown structuresin which the webs, where two or more are utilized, are in substantiallyparallel relationship, This is also true as to the flanges. It isapparent, however, that v such a parallel relationship is not essential,the same advantages of construction being obtainable where either thewebs or the' flanges -or both are in angular relationship one to theother.

It will be understood that while I have herein illustrated and describedcertain preferred embodiments of my invention, the drawings areillustrative only, and typify various shapes and. structures embodyingthe invention and in which changes can be made without departing eitherfrom the spirit of the invention or the scope of my broader claims. Tothis end the term girder is hereinafter utilized in the claims assignifying a body, beam, sill or the like having the characteristicsascribed thereto, the term being one of definition and not one oflimitation.

' I claim: 7

1. In the method of forming a structural shape such as a box girder, thesteps comprising separately preforming web and flange members, securinglugged diaphragm plates to certain of said members transversely betweenthe same, mechanically interlocking the remaining members in position bythe lugs of said plates to form a structure closed on four sides, andwelding the structure including welding along outside joints thereof andwelding from without the structure said lugs in position.

2. In the method of forming a box girder, the steps comprisingseparately preforming web and flange members, securing diaphragm 'platestransversely between longitudinally disposed web members, mechanicallyflange members with said diaphragm plates and with said web members toform a structure closed on four sides, and welding the mechanicallyinterlocked flange members in position including zvelding along outsidejoints 'of the closed strucure.

3. In the method of forming a structural shape, the steps comprisingseparately preforming web and flange members to provide one withparallel lugs and the other with openings to receive said lugs, securingtransverse diaphragm plates to the lugged members, assembling the othermembers with the lugged members so that the lugs are received in saidopenings, the assembled web and flange members constituting a structuralshape closed on four sides, and welding the assembled structural shapeincluding welding along outside joints thereof and welding the lugs inposition- 4. In the method of forming a structural shape, the stepscomprising separately preforming'web and flange members to provide onewith parallel lugs and the other with lug receiving openings, securinglugged diaphra m plates to the lugged members transversely between thesame, assembling the other members with the lugged members so that thelugs of the plates andlugged members are received in said openings, theassembled web and flange,

6. As an article of manufacture, abox girder comprising longitudinalflanges, longitudinal webs disposed edgewise between the-flanges; andtransverse diaphragm plates mechanically interlocked with both the websand the flanges by lugs extending into the webs andthe flanges,

certain .of'said webs and flanges being welded along outside jointstherebetween.

"I; As an. article of manufacture, a box girder interlocking thecomprising a pair of longitudinally extendinglugs, said diaphragm platesbeing fixed in transverse position within said b'ox girder by saidintegral lugs, said webs and flanges being welded along outside joints.

8. As an article of manufacture, a box girder comprising a pair offlanges in substantially parallel relationship, a pair of webs insimilar relationship but edgewise disposed with respect to said flanges,said webs and flanges being welded together along outside joints andforming a structure closed on four sides, and diaphragm platespositioned transversely within said girder by lugs integral therewith,said diaphragm plates bearing against the opposed faces of the flangesto stiffen the girder. v

9. As an article of manufacture, a box girder comprising a pair ofcurved flange members spaced by transverse diaphragm plates, and webmembers mechanically interlocked with said diaphragmplates and weldedalong the outside of the joints with the flange members, the girderstructure formed by the web and flange members being closed on foursides. I

shape comprising an upper compressionplate and a lower tension plateconstituting flanges,

a series of longitudinal webs disposed edgewise jecting in the directionof said first-mentioned between the plates, the webs having parallellyextending lugs and the plates having corresponding openings forreceiving the lugs to mechanically interlock the webs and plates, anddiaphragm plates transversely disposed between adjacent webs and actingas struts between the flanges, the outermost webs of the series beingwelded tov said ,compression and tension plates.

11. As an article of manufacture, a box girder comprising flanges, webscooperating with the flanges to provide a structure closed on four'sides, certain of said webs being welded to said flanges, andtransverse diaphragm plates mechanically interlocking the webs andflanges, the diaphragm plates each having projecting portions receivedin respective openings in a web and flange and subject therein toshearing stresses.

12. As an article of manufacture, a car body comprising a lower tensionand an upper compression member, webs disposed edgewise intermediate thetension and compression members and welded thereto along outside joints,and means for mechanically interlocking said members and webs, saidmembers and webs being of flat rolled stock.

13. As an article of manufacture, a truss in the form of a box girdercomprising upper and lower flanges/ acting as main compression andtension members of the. truss, webs welded to the flanges, andtransversely disposed diaphragm plates mechanically interlocking saidwebs and flanges by liaving projecting portions received incorresponding openings of the webs and flanges for transmitting shearingstresses between the members of the truss, the diaphragm ,plates beingenclosed on four sides and bearing at the top and bottom against theflanges and at both" sides against webs.

14. As an article .of manufacture, a truss in the form of a box girder,comprising primary fwebs, a pair of longitudinally extending flangestension and compression flanges,- diaphragm pIates acting as secondarycompression members or struts for holding said flanges in spacedrelationship, said diaphragms having at their free edges integral shearkeys, and plates welded to said flanges as webs or secondary tensionmembers, said web plates being formed with openings receiving said shearkeys and said shear keys being welded therein, the entire assembly beingfabricated from flat rolled stock.

15. In the method of manufacturing a box girder having a bowed portion,the steps com- Y prising separately preforming correspondingly bowed'web and flange members, providing one with parallel lugs and the otherwith openings to receive said lugs, securing transverse diaphragm platesto the lugged members, assembling the other members with the luggedmembers so that the lugs are received in said openings, and welding theassembled girder including welding along outside joints thereof.

16. As an article of manufacture, a car body comprising longitudinalflanges, a plurality of longitudinal webs disposed edgewise between thelongitudinal flanges, and transverse diaphragm plates mechanicallyinterlocked with both the webs and flanges by lugs extending into thewebs and the flanges, the outside joints between the flanges and certainof said webs being welded.

each closed on four sides and the ends thereof being extended andinterlocked with the end frames. w o

18. As an article of manufacture, a box girder comprising a series oflongitudinally extending webs, a pair of opposed longitudinallyextending flanges cooperating with opposite edges of said webs, anddiaphragm plates transversely disposed between webs and mechanicallyinterlocked with both the webs and the flanges by lugs extending intothe webs and the flanges, certain of said webs and flanges being weldedalong outside joints therebetween.

19. In a car structure, box girders constituting car sills, said boxgirders comprising inner and outer websand upper and lower flangeswelded along outside joints therebetween, and an end frame including atransverse beam, the outer webs of the box girders being extended beyondsaid transverse beam and having openings receiving the ends thereof.

20. In a car structure, box girders constituting car sills, each of saidbox girders comprising web members, flange members, said web members andflange members being welded along outside joints, and transversediaphragm plates having projecting lugs interlocking said plates withcertain'of said members, and an "end frame including a transverse beaminterlocked with the car sills by having the ends of the beam entered inan opening in a web member of each.

21. In a car structure, an end frame including a transverse loadcarrying structural member, trunnion bearings carried thereby, and boxgirders constituting car sills, each of said box girders comprisinginner and outer webs and upper and lower flanges welded together alongoutside joints and mechanically interlocked by transverse diaphragmplates with projecting lugs, said transverse structural member beinginterlocked with the sills by having its ends entered in an opening inthe outer web and abutting the end of the inner web of each sill.

WALTER DE FRIES.

